Automotive OEMs aim to improve the manufacturing time, product quality and safety of powertrain components as they are under tremendous pressure to improve conventional combustion engines’ fuel efficiency. This is required by stringent environmental compliance standards. Environment friendly technologies, such as Daimler’s fuel cell drive - designed to integrate future requirements linked with economic and CO2 emission efficiencies - are now under development but not yet ready for production. Powertrain manufacturers face a changing environment in which they must comply with new environmental restrictions while staying on time for product delivery to the market.

“The fuel efficient, powertrain design process is quite challenging due to the delicate shape and texture of its part components. Design accuracy is key, explains Eric Buehler, senior manger ITP (Information Technology Production) and CAD-CAM systems manger, Daimler AG. With a traditional powertrain manufacturing approach, the CAM (computer-aided manufacturing) and simulation systems run separately, causing lengthy production cycles and inciting errors. With Dassault Systèmes’ technology, we are able to assure high accuracy of engine machined parts, while speeding the manufacturing cycle, ultimately freeing more time for innovative designs.”

DS’s CATIA Machining solution has allowed Daimler to put the latest virtual and environmentally-friendly manufacturing concepts to work as follows:

By incorporating all regulatory compliance requirements into processes built into CATIA, manufacturers can be sure they are meeting the latest environmental standards by testing the product design before engaging in a costly and energy- intensive manufacturing process. The programming tools in CATIA allow for easy adoption of new environment requirements that vary by country and region and are changed frequently by car emission and international standards organizations.

CATIA Machining, programming and simulations components, allow Daimler to digitally define the production of a powertrain component, such as an engine's cylinder head, before starting the "plant" manufacturing process, saving manufacturing energy and time and ensuring the accuracy of each step in the manufacturing process.

CATIA Machining Simulation tools give manufacturing experts at Daimler a chance to virtually test the “choreography” of parts production to ensure the finished product will meet precise design expectations and not damage plant production, costly machines. Adjustments are made virtually until perfection is reached, and only then do operators on the shopfloor launch the live machine performance.

“CATIA Machining solutions are integral for Daimler’s powertrain program,” says Jacques Leveille-Nizerolle, CEO, CATIA, Dassault Systèmes. “By working in tight collaboration, we have enabled Daimler to more efficiently plan, detail, simulate and optimize its powertrain machining in order to drive engine improvements.”